Light-weight drainage line unit employing end-to-end connectors

ABSTRACT

Preassembled drainage line units for a septic tank nitrification field employ a predetermined length of perforated conduit having an aggregation of discrete, crush resistant, light-weight elements surrounding the length of conduit and a perforated sleeve member enveloping the aggregation and bounding the same relative to the conduit with the ends of the conduit extending beyond the sleeve. The drainage line unit is provided with connecting means at each extending end, for end-to-end interconnection with an adjacent drainage line unit.

This application is a continuation-in-part of application Ser. No.07/783,814 filed on Aug. 12, 1991, now U.S. Pat. No. 5,154,543, which isa division of Ser. No. 07/667,460, filed Mar. 11, 1991, now U.S. Pat.No. 5,051,028, which is a division of application Ser. No. 07/164,255filed on Mar. 4, 1988, now U.S. Pat. No. 5,015,123.

This invention relates to a method and apparatus for the installation ofa drainage field, such as a nitrification field employed in a groundabsorption sewage treatment and disposal system; and, in particular,relates to a preassembled drainage line unit and method employing thesame.

BACKGROUND OF THE INVENTION

Conventional drainage systems of the type to which the present inventionrelates typically comprise a horizontally extending perforated conduitdisposed within a drainage trench and surrounded by a quantity of looseaggregate material, such as rock or crushed stone, and covered withcompacted soil. The space between the conduit and the ground occupied bythe aggregate serves to define a drainage cavity in fluid communicationwith the perforations of the conduit.

An example of such a drainage system is found in the nitrification fieldof conventional ground absorption sewage treatment and disposal systemswherein effluent is discharged from a septic tank through the perforatedvent pipe of a nitrification line which is surrounded by a specifiedminimum volume of aggregrate material, such as rocks or crushed stone.The purpose of the nitrification field is to create a storage area forsewage effluent until it can be absorbed by the soil (percolate). Theaggregate material acts to maintain the boundaries of the storage area,prevent blockage of the pipe perforations, promotes the beneficialeffects of biomat development (aerobic bacteria organisms that act onthe sewage colloidal materials to reduce them to soil) and retardsdevelopment of the clogging mat (i.e. the mechanical loss ofinfiltrative capacity at the soil surface interface due to suspendedsolids, bacteria growth and ferrous sulfide precipitation).

Conventional ground absorption disposal systems of that type utilizeseptic tanks and nitrification lines of adequate construction and designvolume in accordance with provisions of local building and health codesgoverning the sanitary disposal of wastes. The effluent from the septictank flows by gravity to an approved nitrification line where the soilprovides for final treatment and disposal of the sewage. The actualprocessing depends upon the class of soil texture (whether sand, loam,clay or mixtures and variations of the same) into which thenitrification line extends. The square footage of area needed for thenitrification field in a trenched system depends on the rate and volumeof effluent to be disposed. The perforated conduit serves the dualpurpose of delivering the effluent to the aggregate filled cavity forabsorption into the soil and to vent sewage gases to prevent localconcentration thereof.

The installation of conventional nitrification lines involves digging atrench and depositing loose aggregate in the form of rock or crushedstone materials into the trench for a minimum depth. The horizontalconduit in the form of a perforated pipe is then laid down on the baseaggregate and surrounded by additional quantities of the aggregate togive required minimum vertical and horizontal dimensions of aggregatesurrounding the pipe. The trench, pipe and aggregate volume andthickness dimensions must all conform to local sanitary disposal codesand specifications. A typical system might, for example, utilize a fourinch minimum inside diameter Schedule 40 PVC pipe or equivalent, set insubstantially horizontal orientation with a minimum fall of not lessthan 1/8 inches per foot. The tubing may, for example, be four- orsix-inch diameter corrugated plastic tubing complying with applicableASTM standards having three rows of holes each 1/2 to 3/4 inches indiameter, spaced longitudinally on approximately four-inch centers. Therows of holes may be equally spaced 120° on centers about the peripheryor three rows may be located in the lower portion of the tubing with theoutside rows being approximately 120° on centers.

The nitrification trenches are constructed as level as possible, withthe fall in a single trench bottom meeting local maximum requirement,such as not to exceed 1/4 inches in ten feet. Trench diameters arechosen to prevent too rapid a rate of sewage discharge or too great astrength into the zone of aeration where organic effluent conversioninto soil occurs. Typical trench diameters are about three feet in widthand two to three feet in depth.

The loose aggregrate placed in the trench to surround the vent pipe istypically required to be clean washed gravel (rock or crushed stone)which is graded or sized between 3/4 and 21/2 inches. The gravel in atypical system is required to be placed a minimum of one foot deep withat least six inches below the pipe and two inches over the pipe, and tobe distributed uniformally across the trench bottom and over the pipe.Soil cover over the nitrification field is specified to be a depth of atleast six inches, or so, with the finished grade over the field beinglandscaped to prevent ponding of surface water and to encourage surfacewater runoff to be diverted away from the nitrification field.

Other mechanisms such as effluent distribution devices (includingdistribution boxes, flow dividers and flow diversion devices), greasetraps, or the like are also included as required and approved by stateand/or local health regulations.

Stepdowns or dropboxes are used where topography prohibits the placementof nitrification trenches on level grade. Their placement and design isin accordance with local specifications.

Conventional installation of drainage fields such as those described,requires the installation of rock, shell, or other labor intensivematerial under, around and over corrugated tubing. Such installationmethods do not lend themselves well to installations involving adverseterrain, working area or unskilled, worker abilities. The requirementfor uniformity and inspections for compliance with state and local codesmakes the installation process tedious and time consuming.

SUMMARY OF THE INVENTION

The invention provides a method and apparatus for the installation of adrainage field, such as a nitrification field employed in a groundabsorption sewage treatment and disposal system, that employs apreassembled drainage line unit for placement in a trench which providesa uniformity and ease of installation heretofore unavailable.

In one aspect of the invention a preassembled drainage line unit isprovided in which loose aggregrate in the form of lightweight materialsis provided in surrounding relationship to a perforated conduit andbounded thereto by a perforated sleeve member. The aggregrate surroundsthe pipe to meet minimum drainage cavity dimension requirements and toprotect the pipe from crushing.

The unit is flexible to provide for ease of installation to conform touneven terrain and winding ditch contours.

The unit provides considerable cost savings in drain installationreducing the machinery, labor, skill and time involved fortransportation and placement.

The units can be installed end-to-end allowing more than just pipe to beinstalled without the added expense of hauling heavier aggregratematerials to job sites and providing a drainage material and methodwhich assures good drainage characteristics and dimensional uniformityat a reasonable price. The invention provides a lightweight, inexpensivefactory-assembled unit that can be quickly installed on site forfootings, open trenches, or with state approval, in nitrification fieldsused as discharge points for septic tanks.

No trucks or heavy equipment are needed to bring the aggregrate to theconstruction site. The only labor needed is to put each unit intoposition, thereby reducing valuable time. Rapid installation providesmore footage at reduced costs. Estimation of workload is easier tocalculate. Proper placement and correct amount of aggregate is assuredfor inspection purposes. Moisture retention and flow is comparable orbetter than systems utilizing gravel aggregate.

A preferred embodiment, described in greater detail below, provides ahorizontal conduit in the form of corrugated or slotted perforated PVCpipe encased as a unit with loose lightweight pieces of plasticaggregrate e.g. plastic puffballs, chips or cubes) that act as acollector and transporter of watery materials. The aggregate in is heldsurrounding preestablished dimensional relationship to the pipe by meansof a perforated sleeve, such as plastic netting, to provideprefabricated units of given length that can be set end-to-end.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention have been chosen for purposes ofillustration and description, and are shown in the accompanyingdrawings, wherein:

FIG. 1 is a schematic section view of a drainage field installationaccording to the prior art;

FIG. 2 is a perspective view of a preassembled drainage line unit inaccordance with the principles of the invention;

FIG. 3 is a perspective view of an aggregrate only preassembled unit inaccordance with the invention;

FIGS. 4A-4C are schematic section views showing the installation of adrainage field utilizing the units of FIGS. 2 and 3 in accordance withthe principles of the method of the invention;

FIG. 5 is a schematic longitudinal section view of the installation ofFIG. 4C for a horizontal level field layout;

FIG. 6 is a schematic longitudinal section view of the installation ofFIG. 4C for a serial distribution multiple-level layout;

FIG. 7 is a view similar to that of FIG. 3 of a second embodiment ofpreassembled drainage line unit;

FIG. 8 is a view similar to that of FIG. 4C showing the installationmethod utilizing the embodiment of FIG. 7;

FIG. 9 is a modified form of the embodiment of FIG. 7;

FIG. 10 is a view of a further modified form of the embodiments shown inFIGS. 7 and 9;

FIG. 11 is a side view, partially in section, of an end cap arrangementfor the embodiment of apparatus shown in FIG. 3;

FIG. 12 is a perspective view of an end cap arrangement for theembodiment of apparatus shown in FIG. 7;

FIG. 13 is a side elevation view of machinery for the manufacture of theassemblies of FIGS. 3 and 4;

FIG. 14 is a top plan view of the machinery of FIG. 13;

FIG. 15 is a side elevation view of an alternate embodiment of themachinery of FIGS. 13 and 14.

FIG. 16 is a cross-sectional view of an alternate form of the end capshown in FIG. 11; and

FIG. 17 is a front view of the alternate form of end-cap depicted inFIG. 16.

Throughout the drawings, like elements are referred to by like numerals.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The method and apparatus of the invention are described by way ofexample in terms of embodiments thereof incorporated for use in theinstallation of a drainage system in the form of a nitrification fieldfor a ground absorption sewage treatment and disposal system.Installation and inspection of the field is to be in accordance withappropriate laws, ordinances and rules governing the disposal of sewage.The details and dimensions of the installation are similar to those forsystems using crushed stone or rock material, no crushed stone or rockbeing required.

In order to consider the invention in context, FIG. 1 illustrates aconventional method for installation of a nitrification line.

As shown, a horizontally extending conduit in the form of a perforatedvent pipe 10 is located within the confines of a nitrification trench 12surrounded by undisturbed soil 14. Loose aggregrate material in the formof rock or crushed stone 15 is placed in the trench 12 to a depth D1 toprovide a specified depth D2 of base aggregrate below the conduit 10 anda specified depth D3 above. A quantity of dirt 16 is added above the topof the aggregrate 15 to a compacted depth D4 and landscaping 17 isprovided above the compacted dirt 16. The depths D1-D4 are chosen toconform to appropriate laws, ordinances and rules governing sewagedisposal for the field site location. Typical sanitary disposalspecifications will require depths D1 of one foot, D2 of six inches, D3of two inches and D4 of six inches, with the top grade of the soil cover16 being landscaped to prevent surface water ponding and to encouragesurface water runoff away from the nitrification field.

The vent pipe 10 in the conventional system illustrated in FIG. 1 may,for example, be four-inch inside diameter Schedule 40 PVC corrugatedplastic pipe with three rows of perforations located in the lowerportion of the tubing, with the outside rows being spaced approximately120° on centers. The bottom of the trench 12 and the orientation of thepipe 10 are set to comply with local code requirements for minimum fall.The trench bottom for a single trench installation may, for a singletrench installation for example, have a fall of 1/4 inches in ten feet,as determined by an engineer's level.

It will be appreciated by contemplation of the representation shown inFIG. 1 that transportation of the heavy aggregrate 15 to and placementin the trench 12 to achieve the required uniformity and depthsurrounding the conduit 10 can be extremely cumbersome andtime-consuming. The installation of such a system in mountainousterrain, for example, can be quite expensive and labor intensiverequiring the heavy aggregrate to be trucked in and sometimes hauledgreat distances for proper placement in positioning in the trench 12. Itwill also be appreciated that for an absorption sewage treatment anddisposal system such as that chosen for discussion purposes,considerable delays will be encountered during the inspection processwhile measurements are taken to determine compliance with the requiredminimum depths of rock above and below the conduit 10. It is not unusualin difficult terrain for a 50-foot long trench to take two to threehours to fill with aggregrate conduit and compressed topsoil.

In a typical prior art drainage field installation method, the trench 12is first dug with a backhoe or similar implement. Then, the base layerD2 of aggregrate material 15 must be carted into location and laid onthe trench bottom. The pipe 10 is then placed centrally above the baseaggregrate and additional aggregrate is added uniformally to surroundthe conduit 10, spacing it centrally widthwise of the trench 12 andproviding the minimum offset D3 of aggregrate material 15 above theconduit 10. Lastly, the topsoil 16 is added above the aggregrate andcompacted to achieve the minimum depth D4 and landscaped to provideappropriate grading for surface water runoff. The placement of theaggregrate 15 below, around and above the pipe 10 is difficult tocontrol and good uniformity of dimension is hard to achieve. It isnecessary during the installation process to continuously measure thedistances around the pipe 10 to ensure that the aggregrate 15 is set inthe required dimensions, and the completed installation is difficult andtime-consuming to inspect.

The present invention utilizes apparatus in the form of a preassembleddrainage line unit 20 (FIG. 2) having a length of conduit 10, such ascorrugated PVC vent pipe, surrounded by a predetermined volume of looseaggregate material 21 which is bounded by a perforated sleeve member 22to maintain uniform minimum dimensions of aggregrate thickness relativeto the conduit 10.

The embodiment shown in FIG. 2 utilizes a horizontal conduit 10 in theform of a corrugated PVC perforated vent pipe encased by a nylon nettingor mesh which is filled with an aggregation of discrete, waterimpervious, crush resistant lightweight elements and secured to the pipeends 24, 25 by means of conventional wires or tie fasteners 26 whichthread through the netting at the open ends of the sleeve 22 to preventthe escape of the loose material 21. The pipe 10 has three rows of holesspaced in conventional manner and located in the lower portion of thetubing 10, with the outside rows spaced 120° on centers. Theperforations provide for fluid communication between the inside of theconduit 10 and the hollows left between the aggregrate material elements21.

A preferred material for the mesh 22 is a seamless plastic mesh tube ofconstruction netting, with an expanded diameter of 13, 18, 24 or 36inches clamped to the pipe 10 at one end of its length and looselyfilled uniformally around the pipe with a plastic packaging materialsuch as 3/4 to one inch chunks of expanded polystyrene, styrofoam orother materials such as are suitable for crush protection in packaging.The other end 24 is tied off after the netting has been packed with theaggregrate material. A suitable netting is like that of commerciallyavailable lobster shipping netting (a heavy duty version of poultry orcitrus produce-type netting), with a hole size of about 3/4-inch, orless. Additional fill material for placement underneath the pipe isgiven in the form of a conduitless casing 30 (FIG. 3) which has asimilar configuration to the unit 20 of FIG. 2, except that the casing22 is tied off at one end, filled with aggregrate material 21, then tiedat the other end, without the insertion of a conduit 10.

The method of installation of a drainage field in accordance with thepresent invention is illustrated in FIGS. 4A-4C, 5 and 6, in the contextof a nitrification field installation utilizing the preassembled unitsshown in FIGS. 2 and 3.

As with conventional installation methods, a trench 12 is first dug tothe required width and depth (FIG. 4A). The trench 12 may be dug, forexample, with a backhoe or similar implement to provide a bank 32representing the interface between the trench 12 and undisturbed soil14. As illustrated, the trench is dug wider than required on one side 33to permit a worker to stand therein during installation. Unlikeconventional systems involving loose gravel aggregrate, a drainagesystem utilizing prefabricated units 20, 30 in accordance with thepresent invention can be readily installed with little difficulty by asingle worker. The units 20, 30 prefabricated into convenient lengths,such as ten-foot lengths, are lightweight and easily carried by theworker to the site and laid in positions alongside the trench 17, asshown.

A convenient size of unit 20 provides a circular cross-section having aradius equal to the radius of the pipe 10 plus the minimum dimension D3of aggregate needed above the pipe 10. To achieve the greater depth D2of base aggregrate required below the conduit 10, an underlayment ofaggregrate material is placed in the trench first. This is done, asshown in FIG. 4B by placing two of the conduit-less, elongatedaggregrate-filled bags 30 side-by-side along the bottom of the trench17, flush with each other and flush with the wall of the bank 32. Tohold the units in place until the trench 12 is filled, a quantity offill material, like dirt 34, may optionally be deposited against theside of the unit 30 at the widened part of the trench 17, as shown. Aunit 20 is then added above the line of contact of the units 30 toposition the horizontal conduit 10 in the desired position within thetrench 12. The unit 20 is preferably secured to the underlying units 30with wire or a plastic tie fastener 35 to present a triangularcross-section, as shown, having a unit at each corner.

This process is repeated for each length of units 20, 30 which areplaced end-to-end for fluid communication from one unit to the nextalong the entire length of the nitrification trench. Each unit is easilylifted down into the trench, placed in position and secured. Theaggregate-filled bag configurations of the embodiments of units 20, 30of FIGS. 2, 3 are rigid enough to support the cross-section dimensionalrelationships between the pipe 10 and the aggregate 21, yet sufficientlyflexible longitudinally to permit the units to follow the contour of thelength of the trench 12. The opposed ends of the lengths of conduit 10of adjacent units 20 are brought together to form a continuousperforated vent pipe.

When the units 20, 30 have been laid and connected end-to-end for thedesired length of nitrification line, topsoil 16 is added to fill theremainder of the trench 12 and compacted to provide a depth of topsoil16 to meet the required margin of fill between the top of the aggregrate21 (i.e. the top of unit 20) and the surface. Compacting may beperformed, such as by overrunning the soil 16 with the large wheels of abackhoe or similar implement.

FIG. 5 shows an installation of drainage field in accordance with FIGS.4A-4C for a horizontal level nitrification field With a substantiallylevel trench and line having a fall not exceeding the maximumrequirements specified by local code. As shown in FIG. 5, the adjacentunits 20, 30 are brought together with the aggregate 21 of one unit 20,30 in close longitudinal fluid flow communication with the aggregrate 21of an adjacent unit 20, 30 and with the end of the vent pipe 10 of oneunit fitted into the facing end of the vent pipe 10 of an adjacent unit.

FIG. 6 shows a similar installation for a serial distribution, multiplelevel layout field having a stepdown suitable where topography prohibitsthe extension placement of nitrification trenches along a level grade.The installation in such situations proceeds as described above withreference to FIGS. 4A-4C and 5, except that a berm or dam 38 ofspecified height (e.g. 10 inches) is formed at the stepdown to meet theflow rate and runoff requirements. The units 30 are placed as before inthe bottom of the trench 12, above the dam and on the step below. At thestepdown, however, a unit 20 runs from the prior unit 20 on the stepabove down to the next unit 20 on the step below, forming a vent path.

The aggregate elements 21 bounded by the perforated sleeve members 22serve to define a drainage cavity 39 (FIG. 4C, 5 and 6) havingpredetermined uniform minimal dimensions D2, D3 of aggregrate elements21 lengthwise of the conduit 10. The loose aggregrate material 21bounded by the netting 22 also prevents the perforated pipe 10 frombeing crushed. The material of the aggregrate is chosen to providedrainage and pipe protection characteristics within cavity 39approximating those of a cavity of the same volume constituted by theloose aggregration of gravel found in conventional designs.

It will be appreciated that the lightweight bags of aggregrated materialconstituting the units 20, 30 provide an ease and uniformity ofinstallation not achievable by the conventional methods in which gravelor crushed stone is positioned and dimensioned on-site within thetrench. The flexibility of the bags is a tremendous asset in laying thenitrification line around curves in adverse terrain. Time and labor issaved and the ease and uniformity of the system being installed is thesame every time.

An example installation of a 50-foot line in a nitrification field wasperformed using four-inch PVC pipe 10, 3/4 to one-inch expandedpolystyrene cubes as aggregate 21, and 13-inch construction nettingsleeves 22 of about 3/4-inch hole size. Pipe and aggregate installation,which would have taken two to three hours to install with gravel oncethe trench had been dug, took less than ten minutes to install. Thetotal job, including digging and filling the trench 12, which wouldnormally have taken three to four hours, was completed in about one andone-half hours. The completed job had a much neater and more uniformappearance. No on-site measurement was required to set the aggregrate torequired specifications. Except for the trench digging and final fillingsteps for which a backhoe was employed, the installation was performedby one worker with relatively little supervision, who carried andpositioned the lightweight aggregrate, pipe prefabricated packages 20,30 himself with no tools or machines other than a shovel for the dirt 34and a fastener for the ties 35 (FIG. 4B). It was found that with a sixinch depth D4 of cover 16 compacted by the back wheels of a backhoe, thevent pipe 10 remained absolutely round with the weight of the seven toeight-ton backhoe standing on it. At the end of installation, the dirtwas dug out from the side of the trench 12 to see the results. The soilinterfacing with the aggregate material 21 was very good. There was atotal depth D1 of 141/2 inches of material 21, 61/2 inches of which wasunder the pipe (depth D2) and 2 inches of which was above (depth D3).The distance from the top to the bottom of the trench 12 was about sixfeet. In the installation example, using 13-inch netting 22 andfour-inch pipe 10 it was found with the deposition thereon of six feetof dirt 16, that the aggregrate material 21 was not crushed and the pipe10 retained its shape with good drainage characteristics.

In other example installations, it was determined that even in the worstconditions with rough terrain and muddy installation, the installationwas quite simple giving a uniform consistency to the drain in asituation where bringing rock to the trench would be most difficult.

A second embodiment of preassembled drainage line unit 40 is shown inFIG. 7, in a view roughly corresponding to the view of the earlierembodiment shown in FIG. 2. The unit 40, like the unit 20 of FIG. 2,comprises a horizontally extending perforated conduit 10 surrounded byan aggregration of discrete, crush resistant, lightweight plasticelements 21. Rather than being surrounded by a perforated sleeve member22 in the form of a netting or mesh envelope as in FIG. 2, however, aperforated sleeve member 41 of rectangular cross-sectional configurationis utilized, with the pipe 10 positioned a required minimum depth D2from the bottom of the sleeve 41 and a required minimum depth D3 fromthe top of the sleeve 41. The sleeve 41 may take the form of aperforated extruded plastic member of desired unit length (e.g. tenfeet). A suitable sectional dimension is 2-3 feet wide and 1-1/4 feethigh. The ends 42, 43 of the unit 40 are shown covered with netting 44,heat-seam welded to the perimeter of sleeve 41 and serving to retain theaggregrate material 21 within the structure 40, at least until it isplaced in the trench 12.

FIG. 8 shows the installation of a nitrification line, similar to thatof FIG. 4C, utilizing the unit 40 shown in FIG. 7. As in FIG. 4C,lengths of units 40 are run end-to-end in the trench 12, with theirconduits 10 interconnected to provide a continuous line and with theloose aggregrate materials 21 of adjacent units 40 being in longitudinalfluid communication. Unlike the unit 20 of FIG. 3, however, the size ofthe unit 40 is selected so that the complete dimensions of theaggregrate drainage cavity 39 are provided by a single unit 40, asopposed to the need for additional aggregrate bags 30 as discussed abovein connection with the installation of FIG. 4C.

As shown, the sleeve 41 is perforated to permit drainage into the soilpercolate 14 adjacent the trench 12. The extruded sleeve 41 should berigid enough to retain the required dimensional extent of aggregrate 21around the pipe 10, but be sufficiently flexible to permit it to followthe expected curvature of an average trench 12. A suitable choice forthe sleeve 41 is extruded PVC with netting sonically welded across itsopen ends to retain the aggregate 21. The extrusion can be corrugated togive it the required rigidity and flexibility.

Although there may be advantages to having the sleeve 22 or 41sufficiently durable and wear resistant so that the lines may be removedfrom the trench at a future date, the main purpose of the sleeve is toretain the measured quantity of aggregrate in position until placed inthe drainage field and a lesser grade material may therefore beacceptable.

The embodiment of the unit shown in FIG. 7, in use as a nitrificationline, is likely to be less easy to snake around a curved trench and isharder to handle for the serial installation (FIG. 6), than theembodiment of unit 20 shown in FIG. 2. However, the embodiment 40 ofFIG. 7 gives the advantage of having the full aggregate cavity 39measurement in one unit. And, as can be seen with reference to FIG. 8,the unit 40 can be dropped into place without the necessity for digginga wider trench 12 as was done with unit 20 (FIGS. 4A-4C), so that thetrench 12 need only be dug as wide as the width dimension of the sleeve41. Embodiments of prefabricated units as in FIG. 7 may also bedesirable in certain drainage situations other than nitrification lines,such as footings or open trenches used for dewatering saturated soils bycollecting and conveying ground water to a drain pipe for discharge at aremote location.

FIGS. 9 and 10 show alternate embodiments 40', 40" of the preassembleddrainage line unit of FIG. 7. The embodiment 40' shown in FIG. 9 issuitable especially for footage drain and other applications, whereadded strength of sleeve 41 may be required. FIG. 9 utilizes an extrudedsleeve member 41' which has diagonally extending webs 47, 48 whichpartition the cavity encompassed by the sleeve into longitudinallyparallel segments 49, 50, 51, each of which receives a measured amountof aggregrate material 21. The webs 47, 48 provide added rigidity to thestructure and define the position for placement of the conduit pipe 10.As shown in FIG. 9, each web 47, 48 extends from an upper cornerinternally of the sleeve 41' to a line 52 running along the inside ofthe base of the structure to define a V-shaped portion into the vertexof which the conduit 10 fits. Webs 47, 48 are perforated to permit fluidcommunication between the portions 49, 50 and 51.

The embodiment 40", shown in FIG. 10, utilizes a vent channel 61 formedin the upper portion of the sleeve 41" as a vent conduit rather thanutilizing a separate vent pipe conduit 10 as in units 40, 40' of FIGS. 7and 9. The unit 40" is, thus, constructable from an extruded sleeve 41"by packing a lower portion 62 of the unit 40" with loose aggregratematerial 21, the vent channel 61 in the upper portion being integrallyformed with the extrusion of the sleeve 41". The channel 61 is definedby the top 63 of the sleeve 41" and a horizontal partition 64 extendingbetween sidewalls 65, 66 from points partway down from the top 63, andrunning parallel to the top 63 for the full length of the unit 40".Structural reinforcement of the channel 61 to prevent collapse of thestructure 64 when weighted down from above is provided by diagonalcross-webbing 67. The cross-webbing 67 and the partition 64 areappropriately perforated to provide fluid communication between thechannel 61 and the aggregrate 21. The top 63 may be perforated, asappropriate, according to the use to be made of the channel. For anitrification field application, the channel 61 takes the place of ventpipe 10 of FIG. 7. The top 63 is, thus, perforated and additional units40", with or without vent channels 61, can be added above the unit 40",as needed, to provide additional aggregate material 21 to meet localcode requirements for depth D3 of material 21 above the vent channel 61.

A provision can be made for the convenient end-to-end connection betweenperforated pipe 10 of one unit 20, 40, 40', 40" and another. FIG. 11shows such a provision for the connection of units 20 of FIG. 2.

As shown in FIG. 11, end caps 71, 72 of PVC plastic are snap-fitted tothe ends 24, 25 of the perforated pipe 10. The end cap 71 provides amale fitting and the end cap 72 provides a complementary female fitting,so that the male fitting of an end cap 71 of one unit 20 will mate withthe female fitting 72 of an end cap 72 of an adjacent unit 20. The endcap arrangement provides a snap-in system for interconnecting units 20end-to-end, without requiring the contorting and threading of one pipe10 into the other. The end caps 71, 72 preferably take the form of aclamshell-type structure with a living hinge, as shown, the male endbeing provided with a yieldable circumferential flange 73 that snapsover one run of corrugation of the pipe 10 at its inside end and acentral tubular extension 74 at its outside end which inserts into acorresponding central tubular opening 75 opening to the outside end ofthe female end cap 72. Positioning lugs 76, 77 protrude above and belowthe tubular extension 74 for likewise insertion into corresponding lugreceiving apertures 78, 79 located above and below the tubular opening75. The end caps shown in FIG. 11 are circular in form with inwardlyfacing outer cylindrical portions 68 that extend peripherally around theends 69, 70 of the sleeves. When end caps are used, the ends 69, 70 ofthe sleeve 21 (see FIG. 1) can be compressed by circumferentialclamping, such as by a wire strap or fastener 80 (FIG. 11), rather thantying to the pipe ends 24, 25 at 26 (FIG. 1). The clamping will keep theaggregate contained until the end caps are applied.

FIG. 12 illustrates a similar end cap arrangement for a rectangularunit. A male end cap 81 of box-like rectangular construction has atubular extension 82 projecting centrally therefrom for mating with acentral opening 83 in a corresponding female end fitting 84. Thefittings 81, 84 are perforated to permit fluid communicationlongitudinally between adjacent units. The end caps 81, 84 are ofsemi-rigid material and have provision for fastening to the remainder ofthe rectangular unit. Fastening means, as shown in FIG. 12, may alsotake the form of a plurality of teeth peripherally spaced about theperimeter of the inside ends of the fittings 81, 84, which suitablycapture the ends 69, 70 of netting to permit the rectangularconfiguration of the embodiment of FIG. 7 to be accomplished with a webor netting similar to that of unit 20 of FIG. 2, without the necessityfor a rectangular extrusion 41.

Machinery 90 suitable for the manufacture of prefabricated drainage lineunits, such as units 20, 30 discussed above, is shown in FIGS. 13 and14. A tubular mandrel 91 is positioned horizontally on a support 92comprising legs 93, 94 and a horizontal support surface 95 extendingtherebetween. The mandrel has an upper opening 96 into which feeds theexit port of a funnel-like hopper 97 which serves to supply a quantityof aggregrate material 21 by gravitational feed into the interior of themandrel 91. An annular plate or disc 98 is vertically concentricallypositioned for reciprocal movement along the longitudinal axis of themandrel 91. An arcuate gate 99, of partial cylindrical shape, extendsbackwardly from the top of the plate 98 along a contour parallel withthe internal dimension of the top of the mandrel 91. Transverse membersor lugs 101, 102 extend laterally radially outward from opposite sidesof the disc 98 through longitudinal slots 103, 104 in the mandrel wall.Hydraulic piston assemblies 105 106 located externally of the mandrel 91connect to the members 101, 102 to drive the disc 98 and gate 99 inreciprocal motion in response to selective control of hydraulic fluidflowing in fluid lines 107, 108.

A length of corrugated PVC perforated tubing 10 is placed axially withinthe mandrel 91 to extend from the mandrel rear opening 109 to themandrel front opening 110, through a central opening 111 in the disc 98.A length of netting 22 is received in gathered position 112 peripherallyabout the circumference of the mandrel 91 at its discharge end 110. Atie fastener 26 is applied to fix or cleanup the netting 22 about thefree end of the conduit 10 extending out of the opening 110. The disc 98and gate 99 assembly is then drawn rearwardly by contraction of the armsof the pistons 105, 106 attached to the lugs 101, 102. As the disc 98 isbrought from its forward (solid lines in FIG. 13) to its rearward (dotand dashed lines in FIG. 13) position, the gate 99 clears the opening 96of the hopper discharge port and a quantity of aggregrate 21 drops intothe mandrel 91 to surround the pipe 10 passing therethrough, filling thehollow created when the disc 98 is drawn back. The arms of pistons 105,106 are then extended by control of fluid in the lines 107, 108,bringing the disc 98 forward again. This movement repositions the gate99 over the hopper discharge port 96 preventing further discharge ofmaterial 21 into the interior of the mandrel 91. The forward movement ofdisc 98 also pushes the newly deposited aggregrate material 21 forwardin the annular space surrounding the pipe 10 into the extended ofnetting 22, unwrapping and drawing with it a new portion of the gatheredmaterial 112. Because the front end of the pipe 10 is tied to thenetting 22, pushing additional aggregrate into the netting to extend italso feeds a new length of pipe through the hole 103 in the disc 98 outof the front end 110 of the mandrel 91.

This reciprocation process continues with back and forth movement of thedisc 98 under control of the hydraulic pistons 105, 106 until the otherend of the sleeve 22, or the desired length of unit 20, is reached. Atthis point, the end or portion of the sleeve 22 closest to the mandrelexit 110 is attached with a tie or similar fastener 26 (FIG. 1) or clamp80 (FIG. 11) to the pipe 10, and the pipe is cut rearwardly of the tiepoint, releasing one completed length of unit 20. A new gathered netting22 is then tied or clamped to the cut end of pipe 10 remaining exposedat the discharge opening 110 of the mandrel 91, and the machine 90 isnow ready for assembling the next unit 20.

To use the same machinery 90 for manufacture of the aggregrate only bag30 shown in FIG. 3, the process proceeds in the same manner except thatno pipe 10 is introduced into the mandrel 91. Furthermore, to preventleakage of the aggregrate material 21 back through the rear of themandrel 91 the opening in the disc 98 normally occupied by the pipe 10covered, as with a plate (not shown). A length of sleeve netting 22 iscircumferentially mounted at the discharge port 110 of the mandrel 91with its front end joined and tied at its center. The pistons 105, 106are then operated to reciprocate the plate-covered disc 98 backwards andforwards, alternately opening and closing the hopper discharge port 96to fill the bag 22, until the desired length of unit 30 is reached theopen end of the aggregate-filled bag 22 is then likewise tied at itscenter to contain the aggregate.

FIG. 15 illustrates an alternative mechanism 90' for the aggregrateloading process that utilizes an auger 121, instead of a reciprocatingdisc, to bring the aggregrate 21 forward within the mandrel 91. Theauger comprises a helical blade 122 positioned peripherally of a hollowshaft in the form of tubing 123. The shaft 123 extends rearwardly of themandrel 91 and is supported for rotation within a bearing 124. Asprocket 125 fixed to the tubing 123 at a position rearwardly of thebearing 124 serves to accommodate a chain 126 which is driven by asprocket 127 mounted on the drive shaft of an electric motor 128. Theinside diameter of the tubing 123 is sufficiently great to permit thepassage therethrough of tubing 10. Plastic netting 22 is gathered on thecircumference of the discharge port as with the embodiment of machineryshown in FIGS. 13 and 14 and the method of filling the sleeve withaggregrate material proceeds in a similar fashion, with the augerdisplacing the aggregrate 21 rather than a reciprocally moving disc.Conduit 10 in the form of corrugated tubing may be fed continuously intothe rear 109 of the mandrel 91. For conduit 10 of four-inch inchdiameter tubing, tubing 123 may be five-inch tubing. The mandrel 91 cansuitably be a ten-inch pipe. A tension bar 129 can optionally beprovided to hold the end of the plastic netting to prevent its releaseuntil the proper amount of material 21 has been stuffed into the bag.

As can be appreciated, similar machinery can be used to load theembodiments shown in FIGS. 7-10. The end caps of FIGS. 11 and 12 can beadded before and after loading as part of the process. When end caps areused, upon completion of the filling of a unit length of netting withaggregate, two spaced clamps 80 (FIG. 12) can be applied automatically,such as by a strapping machine, and the pipe cut between two clamppositions, the one clamp serving to tie off the rear of the completedunit and the other serving to tie off the front of the next unit.

As is clear from the foregoing, the invention provides for easier, moreuniform installation of drainage fields by providing a preassembleddrainage line unit for placement in a trench. It will be appreciated bythose skilled in the art to which the invention relates that althoughthe invention has been described in terms of embodiments utilized for anitrification field employed in a ground absorption sewage treatmentdisposal system, the principles of the invention may also beincorporated into footings, open trenches and other drainage systems inwhich an aggregate filled cavity conveys watery substances to or from adrain pipe. And, while the foregoing discussion has focused on drainagefields with lines, it is clear that the same principles apply todrainage beds.

It will be a}appreciated that other forms and cross-sections of conduit10 can be used in place of those shown and that the loose aggregate fill21 can be constituted by material other than the specific materialssuggested in the preferred embodiments above. It may be possible, forexample, to use styrene, styrofoam or recycled plastic pieces of PVC.They may take the form of tubes, chips or other suitably sized andgraded chunks, such as "peanut" styrofoam pieces. They may also be sizedand fabricated by recycling polyurethane, polypropylene plastics whichare recovered in bulk and put in a chipper or cut with a hot screen. Theaggregate material may also be in the form of plastic balls; however,such shapes may be more expensive.

FIGS. 16 and 17 illustrate an alternate form of a universal end capsuitable for use as an alternate to the end cap arrangement shown inFIG. 11. In FIGS. 16 and 17, the universal end cap is referred togenerally by the reference numeral 210, and includes a central opening212 and an annular extending surface 214 which is preferably coplanarwith the ends 24, 25 of the two predetermined lengths of conduit 10 towhich the end caps 210 are connected in an end-to-end alignment, asdepicted in the side view of FIG. 16. Each universal end cap 210includes a male protuberance 216 extending from the outer extremity ofthe surface 214, and an opposing female opening 218 dimensioned toreceive an opposing male protuberance to 216. Each universal end cap 210is further provided with tabs 220 along the periphery of the centralopening 212, for engagement with the outer periphery of thecorresponding length of conduit 10 (note FIG. 16). As shown in FIG. 17,each tab 220 is defined by a supporting spine 222 and two relief grooves224, to impart flexibility to each tab 220.

Those skilled in the art to which the invention relates will appreciatethat there are other substitutions and modifications that may be made inthe described embodiments without departing from the spirit and scope ofthe present invention, which is defined by the following claims.

What is claimed is:
 1. A preassembled drainage line unit for use in adrainage field employed in a sewage treatment and disposal system fordelivering fluid from a source of sewage effluent for absorption intothe ground, the drainage line unit comprising:a predetermined length ofperforated conduit including means for connecting the source and toanother predetermined length of perforated conduit of adjacent drainageline units; an aggregation of discrete elements surrounding eachpredetermined length of conduit; a perforated sleeve member envelopingthe aggregation of each unit and bounding the same relative to thelength of predetermined conduit, to define an aggregate filled draincavity with a portion of each conduit extending beyond the opposing endsof the perforated sleeve member, the drainage cavity havingpredetermined minimum dimensions in directions outwardly of the conduitfor providing drainage characteristics similar to those of a cavityconstituted by an aggregation of rock or crushed stone; connecting meansmounted over the extending end of each predetermined length of conduit,the connecting means being interconnected at each end of each unit so asmate in conduit interconnecting relationship with an end of another unitbrought into end-to-end alignment therewith; and wherein the connectingmeans comprises a universal end cap at each end of each unit, each endcap having both a male interconnecting configuration and a femaleinterconnecting configuration and further including a recess, saidrecess defining means for receiving a portion of said perforated sleevemember and of said aggregation of discrete elements, whereby each end ofeach unit is interconnectable with either end of each other unitirrespective of orientation.
 2. The drainage line unit recited in claim1 wherein each universal end cap comprises an annular member having acentral opening for receiving an end of the perforated conduit, aprotuberance extending generally axially from the periphery of theannular member, and an opening along the periphery of the annular memberdefining means for receiving a protuberance of an end cap on an adjacentunit.
 3. The drainage line unit recited in claim 2 further comprisingtab means for engaging a side of the perforated conduit.
 4. The drainageline unit recited in claim 2 wherein the annular member has an outersurface the extremity of which is generally coplanar with the end of theperforated conduit, the protuberance and the opening positioned on theouter surface.
 5. In a drainage field employed in a sewage treatment anddisposal system for delivering fluid from a source of sewage effluentfor absorption into the ground, a preassembled drainage line unitcomprising:a predetermined length of perforated conduit connected todelivered fluid from the source; an aggregation of discrete,light-weight bodies of plastic material surrounding the conduit; aperforated sleeve member enveloping the aggregation and bounding thesame relative to the conduit to define an aggregate-filled drainagecavity which provides drainage characteristics similar to those of acavity of the same dimensions constituted by an aggregation of rock orcrushed stone; a first connecting means mounted over one end of thepredetermined length of conduit and a second connecting means mountedover the other end of the predetermined length of conduit, theconnecting means being interconnected at one end of a first unit inconduit interconnecting relationship with an opposing end of anothersuch unit which is brought into end-to-end alignment therewith andwherein the connecting means comprises a universal end cap at each endof each unit, each end cap having both a male interconnectingconfiguration and a female interconnecting configuration and furtherincluding a recess, said recess defining means for receiving a portionof said perforated sleeve member and of said aggregation of discreteelements, whereby each end of each unit is interconnectable with eitherend of each other unit irrespective of orientation.
 6. A drainage fieldemployed in a sewage treatment and disposal system for delivering fluidfrom a source of fluid effluent for absorption into the ground, thedrainage field comprising:a trench; a plurality of individual,preassembled drainage line units placed in end-to end fluidcommunicating relationship within the trench, each of the unitscomprising a horizontally extending predetermined length of perforatedconduit connected in fluid communication with the source, an aggregationof discrete, crush resistant, light-weight elements surrounding theconduit, a perforated sleeve member enveloping the aggregation andbounding the same relative to the conduit to define an aggregate-filleddrainage cavity through the perforations of the conduit with thedrainage cavity providing drainage characteristics similar to those of acavity of the same dimensions constituted by an aggregation of rock orcrushed stone, and connecting means fitted to each end of eachpredetermined length of perforated conduit for interconnection with theconnecting means of another drainage line unit fitted in end to endalignment therewith, the connecting means comprising a universal end capat each end of each unit, each end cap having both a maleinterconnecting configuration and a female interconnecting configurationand further including a recess, said recess defining means for receivinga portion of said perforated sleeve member and of said aggregation ofdiscrete elements, whereby each end of each unit is interconnectablewith each end of each other unit irrespective of orientation; andcompacted top soil placed above the units to fill the trench.